Natural Fibres and the Environment Natural Fibres and the Environment ––

environmental benefits of environmental benefits of

natural fibre production and usenatural fibre production and use

Rome, Rome, 20 10 0820 10 08

Jan E.G van DamJan E.G van Dam

Div Div BiobasedBiobased ProductsProducts

Wageningen URWageningen UR

BioBio""basedbased economyeconomy

…….the solution for .the solution for sustainable developments sustainable developments

...?......?...

Natural Natural fibresfibres

…….the solution for .the solution for environmental environmental

improvement ...?...improvement ...?...

Natural Natural fibresfibres

•• Vegetable Vegetable fibresfibres (cellulose)(cellulose)–– Seed hairs: Seed hairs: Cotton, Kapok Cotton, Kapok

–– BastBast fibresfibres:: Jute, Jute, KenafKenaf, Flax, Hemp, Ramie, Flax, Hemp, Ramie

–– Leaf Leaf fibresfibres:: Sisal, HenequenSisal, Henequen

–– Leaf sheath:Leaf sheath: Abaca, banana Abaca, banana

–– Fruit Fruit fibresfibres:: CoirCoir

•• Animal Animal fibresfibres (protein)(protein)–– Wool:Wool: Sheep, Camel, Goat, LlamaSheep, Camel, Goat, Llama

–– Silk:Silk: SilkwormSilkworm

VariousVarious CropsCrops and and RegionsRegions

Cotton

Cotton

Flax

Kenaf

CoconutCoconutSisal

HempBamboo

Cotton

Ramie

Abaca

Sisal

Jute

Coconut

CoconutHenequen

Cotton

Wool

Silk

Natural Natural fibresfibres ??

•• Mineral Mineral fibresfibres–– Asbestos Asbestos

–– Stone wool Stone wool

–– Glass Glass fibrefibre

•• Man made Man made fibresfibres–– Viscose / rayon or regenerated celluloseViscose / rayon or regenerated cellulose

–– Regenerated protein Regenerated protein fibrefibre (soybean, casein)(soybean, casein)

–– Polymer Polymer fibrefibre (polyester)(polyester)

–– ChitosanChitosan (from chitin)(from chitin)

Natural Natural fibresfibres ……??

•• Dietary Dietary fibresfibres

•• Food supplements (Food supplements (prebioticsprebiotics) and health ) and health productsproducts

Natural Natural fibresfibres end useend use

•• Textiles, yarns and woven fabricsTextiles, yarns and woven fabrics

•• Ropes, twines, cordage, netsRopes, twines, cordage, nets

•• NonNon77woven fabrics, tissueswoven fabrics, tissues

•• CompositesComposites

•• Paper and boardPaper and board

•• FibreFibre boards and insulationboards and insulation

•• BioBio77ethanolethanol value additionvalue addition

•• Mulch and compostMulch and compost

€

3000

2000

1000

0

€ / Mg

Agriculturalproduction

Fibre production

Textile fibre

Cellulose

Non-woven

Pulp

GeotextilesFourageAnimal BeddingEnergyCompost

Fibre crops

Agro residues

Waste biomass

Energy crops

Market

Productioncosts

Addedvalue

Conversion steps

Value addition in fibre conversion

Hemp / flax fibre quality chain

€primary processing

spinning

weaving

consumer

marketing &design

agricultureagricultural production

Natural Natural fibresfibres production chain

AAgricultural production

BFibreExtractionProcess

C1Textile fibreprocessing

C2Non7textilefibreprocessing

D1Textilemanufacturing

D2Paper / composites / nonwovenmanufacturing

EConsumeruse

FDisposal

CO2

seeds

leaves

dust

seeds

water/irrigation

fertiliser

pesticides

energy

A " Agricultural Production

sowing

weeding, thinning

harvesting

drying / defoliation

transport storage

Natural Natural fibresfibres production steps A

B

Mechanized harvesting of hemp

B shives

short fibretow

waste water

energy

water

B " Fibre extractionprocess

retting / degumming

fibre extraction / decortication / scutching

fibre cleaning / washing

drying

Natural Natural fibresfibres production steps B

C1

C2

A

transport storage

Dew retting of flax

Retting of coir

Natural Natural fibresfibres production steps C1

D1

B

shives

short fibretow

waste water

lubricants

energy

waterbleachingchemicalsdyes

C1 " Fibre processing

softening / lubricatinghackling / carding /

drawing

spinningweaving

finishing / dyeing / bleaching

C2

transport storage

Processing of Coir

• Hand spinning of coir yarn

Wet processing of Coir

• Cold peroxide bleaching of coir

Wet processing of Coir

• Traditional coir dyeing in wood heated tubs.

Eco"friendly bleaching and dyeing of coir

Natural Natural fibresfibres production steps C2

C1

B

shives

short fibretow

waste water

D2

black liquor

chemicals

waste water

C2 " Fibre processing

pulping/

compounding /

web formation/

blending

chemicals/

resins

polymers

transport storage

NonNon""wood pulpingwood pulping

100% (< 7% total pulp)100% (< 7% total pulp)21.321.3Total WorldTotal World

90%90%19.219.21010"" Country TotalCountry Total

71%71%9%9%1%1%1%1%1%1%1%1%1%1%1%1%1%1%1%1%

15.215.22.02.00.30.30.30.30.30.30.30.30.20.20.20.20.20.20.20.2

ChinaChinaIndiaIndiaMexicoMexicoPeruPeruPhilippinesPhilippinesIndonesiaIndonesiaUSAUSAThailandThailandColombiaColombiaBrazilBrazil

% of total% of totalCapacity (Million tons)Capacity (Million tons)CountryCountry

Non"wood pulp fibres

• Cotton linter Abaca Banknote and security paper

Tea bags, filtersFlax sausage casingHemp cigarette paperKenaf electrolyte condensor paper

• Straw • sugar cane bagasse paper board / wrapping paper• Bamboo

Natural Natural fibresfibres production steps D"F

E

D1 " End"product manufacturing

yarnsapparel fabrics

household textilesfurnishings and wall covering

upholstrysacking

D2 " End"product manufacturing

paper & boardnon7wovenpackaging

fibre boards and panelsinsulation

horticultural productsgeotextiles

composites

energy

recycling raw materials

E " Consumer useF

disposal

transport storage

transport storage

Life cycle assessment framework

Goal and scope definition

Inventoryanalysis

Impact assessment

Interpretation

Product Developmentand improvement

Stategic Planning

Public Policy making

Marketing

Other

Quantitative environmental impact LCA

•• Criteria .. Criteria .. Standards ISOStandards ISO771404014040774343–– Whole life cycle of a product including its byWhole life cycle of a product including its by77productsproducts

–– Raw material acquisition to product disposalRaw material acquisition to product disposal

•• Comparison between diverse environmental Comparison between diverse environmental impact factorsimpact factors–– Emissions and consumption of resourcesEmissions and consumption of resources

•• EcoEco77indicators indicators –– weighing / classification factors weighing / classification factors

•• Interpretation Interpretation

Weighing factors (Eco7indicator)

•• Green house effect Green house effect COCO22 2.52.5

•• Ozone layer depletionOzone layer depletion CFKCFK 100100

•• AcidificationAcidification (Sulfur)(Sulfur) 1010

•• EutrophicationEutrophication (Phosphate)(Phosphate) 55

•• SmogSmog (Methane)(Methane) 2.52.57755

•• PesticidesPesticides 2525

•• Heavy metalsHeavy metals (Lead)(Lead) 55

World fibre production

World fibre production 1920-2006 (kton)

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

1915 1925 1935 1945 1955 1965 1975 1985 1995 2005

Cotton

Synthetic (petro-based)

Man-made cellulose fibres *

Cotton vs polyester LCA

•• Cotton requires less fossil resources Cotton requires less fossil resources

(energy, fertilizer), but higher demand for water(energy, fertilizer), but higher demand for water–– Organic cotton (agrochemicals) Organic cotton (agrochemicals) vsvs GMOGMO

No dramatic differences inNo dramatic differences in

•• Textile processing (dyeing and bleaching) Textile processing (dyeing and bleaching)

•• Longer functional lifetime for blended fabricsLonger functional lifetime for blended fabrics

•• Lower energy requirement in laundering for Lower energy requirement in laundering for synthetic textiles synthetic textiles

Agrofibre reinforced composites

•• AgrofibreAgrofibre compounds for compounds for injection moulding injection moulding implementation at implementation at commercial scalecommercial scale

•• Strength of the Strength of the elementary fibre is elementary fibre is important not that of the important not that of the fibre bundlefibre bundle Injection moulded products from

natural" fibre/plastic granules

Technology for natural fibre reinforced plastics

Injection moulding

Raw materials agrofibre

PP

Granules

Extrusion

Fibre composites in automotive

• Applied as nonwoven mats combined with plastic sheets

• LCA advantage in weight reduction

Use of natural fibres in automotives

Natural fibres vs synthetic / glass fibre

•• In the production phase the score of In the production phase the score of

fibrefibre crops on COcrops on CO22 and greenhouse gas emission and greenhouse gas emission levels, fossil energy consumption and resources levels, fossil energy consumption and resources is much betteris much better

•• In composites, blended textiles or nonIn composites, blended textiles or non77wovenswovens the the impact of synthetic resins on the LCA is largeimpact of synthetic resins on the LCA is large

Natural Natural fibresfibres vsvs synthetic / glass synthetic / glass fibrefibre

•• The The utilisationutilisation phase phase

contributes most to the impactcontributes most to the impact

•• Weight reduction in composites in automotive Weight reduction in composites in automotive applications contributes to fuel savings applications contributes to fuel savings

•• For the same mechanical performance heavier For the same mechanical performance heavier constructive elements with natural constructive elements with natural fibrefibre is requiredis required

Cradle to Cradle Cradle to Cradle C2CC2C

•• W. McDonough M. W. McDonough M. BraungartBraungart–– Remaking the way we make thingsRemaking the way we make things

•• EcoEco77efficient / effective design of productsefficient / effective design of products

•• Reuse of waste to make new products Reuse of waste to make new products –– Waste becomes food.. Ever lasting cyclesWaste becomes food.. Ever lasting cycles

•• Ford / NIKE / Ford / NIKE / ……many companies followmany companies follow

BioBio77based economybased economy and and C2CC2C

•• Green Architecture and building Green Architecture and building

•• Automotive industries Automotive industries …… sustainable commercesustainable commerce

•• Nutrient Nutrient UpcylingUpcyling, Triple, Triple77TopTop77Line, Line,

EcoEco77effectiveness, Industrial design, effectiveness, Industrial design,

•• Technical and biological nutrients for Technical and biological nutrients for

..everlasting consumption.. (?)..everlasting consumption.. (?)

Ecological footprintEcological footprint

Land area required per person to maintain his lifestyleLand area required per person to maintain his lifestyle

(incl. food, energy, water, housing, clothing, travel, etc.)(incl. food, energy, water, housing, clothing, travel, etc.)

BioBio77based economybased economy and Sustainable developmentsand Sustainable developments

•• KYOTOKYOTO and COand CO22 neutral productionneutral production

•• Transition processTransition process

•• Renewable resources for Renewable resources for energyenergy and and productsproducts

•• Exploitation of biomass from agroExploitation of biomass from agro77industrial residuesindustrial residues

•• Value addition in materials, and Value addition in materials, and ‘‘greengreen’’ chemicalschemicals

Competing claimsCompeting claims for biomass resourcesfor biomass resources

Sustainableustainable productionproduction

foodfood supplysupply securitysecurity

land land useuse

deforestationdeforestation

ruralrural developmentdevelopment

RapidRapid expansionexpansion of of demanddemand forfor energyenergy purposespurposes

DEVELOPMENT OF BIOREFINERYDEVELOPMENT OF BIOREFINERY

R&D activities & sustainable developmentR&D activities & sustainable development

•• renewable energy from biomass residuesrenewable energy from biomass residues

•• building materials, recyclingbuilding materials, recycling

•• ‘‘greengreen’’ chemicals & polymeric productschemicals & polymeric products

•• alternative technologies and sources for cellulose alternative technologies and sources for cellulose textile production (bamboo)textile production (bamboo)

•• horticultural substrates & biodegradable erosion horticultural substrates & biodegradable erosion control materialscontrol materials

and many otherand many other

•• AgroresiduesAgroresidues of food and nonof food and non77food cropsfood crops–– cotton stalks cotton stalks

–– rice straw / hull rice straw / hull

–– sugar cane sugar cane bagassebagasse

–– corn cobscorn cobs

–– coconut huskcoconut husk

–– jute sticksjute sticks

–– palm oil residuespalm oil residues

–– eucalypt barkeucalypt bark

–– verge grasses, etcverge grasses, etc

Renewable raw materialsRenewable raw materials

Obvious surplus EFB

OptionsOptions forfor sustainablesustainable residueresidue utilisationutilisation

BioBio77dieseldiesel ((residualresidual oiloil / / pressingpressing cakes)cakes)

BioBio77gasgas, H, H22 / ABE and ethanol / ABE and ethanol fermentationfermentation

BioBio77polymerspolymers (PLA, PHA)(PLA, PHA)

BioBio77oiloil pyrolysispyrolysis / / CharcoalCharcoal

FibresFibres forfor paper, building boards and paper, building boards and compositescomposites

DissolvingDissolving cellulosecellulose

““greengreen”” chemicalschemicals ((ligninlignin and and furfuralfurfural adhesivesadhesives))

precipitation Coatings Biopolymersextract

sugars Alcohol / H2

effluentdryingchoppingpelletising

residue

Feedgassifycombustion

Energy

waste compost

compostingdisposal

silica

fermentation

tar

ash

Protein, lipids

Biomass

fuel

extraction modification

refining fibre pulp Paper / boardadhesives

Biorefinery (cascading) of biomass

Coconut biorefinery C2C example

Biomass from agroBiomass from agro77industrial residuesindustrial residues

World production capacity coconut husk

15720

million tons /

year

Husk preparation (CFC/ FAO project)Husk preparation (CFC/ FAO project)

Coconut husk

Opening Milling

Coconut

Building and construction materialsBuilding and construction materials

BinderlessBinderless boardsboards

First production lineBatangas Phillipines

• Multi daylight

press

15 tons/d capacity

Market: Japan

Heavy duty packaging

(pallets wood subsitute)

Economical evaluation

• Production: – 10,000 tonnes board/year

– 400,000 boards 4 ft*8 ft* 0.25 inch� 1,333 boards/day

• Raw material– 77,650,000 husks/year

� 260,000 husks/day

• Investment estimate– 650,000 US$

Blue print business plan

• Capital investment plan – Production scale 10,000 tonnes board/year

– Location / site

• Marketing plans– Eco7labeling (FSC) / Fair trade / quality certification

– CDM / carbon credits

• Social development plans– Education plan

– NGO involvement

• Product development plan

Business roll out plan

• Demonstration industrial production – Production units 10,000 tonnes board/year

– Integrated whole nut utilisation (oil, press cake, shell, husk)

– N. Sulawesi, Indonesia / Mindanao, Philippines

– Franchising (?)

• Common marketing strategy – Trade mark / brand retail

– Niche products (packaging / furniture) value addition

• Social development strategy– Village level involvement (housing / labour / schooling..)

Non7technical aspects of implementation plans

Financing structures and commercial developments

Clean development mechanism (CDM) and carbon trading

Common sales, common market, fair trade / ecolabeling

Socio7economic aspects – food vs fuel (biodiesel)

Political implications

Sustainability criteria

• Ecological .. Wood substitute products

to prevent deforestation

• Carbon credits / CDM

• Socio7economic – labour, income and housing

• Addressing poverty by supporting the incomes and livelihoods of commodity producers

• Fair trade and quality certification

•• The Project seems more than feasibleThe Project seems more than feasible

•• Prospects to apply for external funding are Prospects to apply for external funding are very goodvery good

•• This kind of project is exactly what is needed This kind of project is exactly what is needed as a pilot/example for other regions and as a pilot/example for other regions and countriescountries

Conclusions fibres and the environmentConclusions fibres and the environment

Ecological impact assessments are complex

and use incomparable weighing factors

The impact of primary agricultural production of fibre crops on the LCA is marginal

Restricted information available from industrial fibre production chains

Conclusions fibres and the environmentConclusions fibres and the environment

The environment has become a The environment has become a major drivermajor driver

for industries and governmentsfor industries and governments

Natural fibres are a major renewable (CONatural fibres are a major renewable (CO22 neutral) neutral) resource for bioresource for bio77based economical developmentsbased economical developments

Overall ecological performance of a crop improves when Overall ecological performance of a crop improves when residues and byresidues and by77products are better usedproducts are better used

Conclusions fibres and the environment Conclusions fibres and the environment

Certification Certification of the sustainability of of the sustainability of

the fibre production chains for biomass energy and the fibre production chains for biomass energy and products is needed products is needed

MultiMulti77stakeholder involvement needed: stakeholder involvement needed:

Include outsider (food Include outsider (food vsvs nonnon77food) industries food) industries involved in energy and fibre productsinvolved in energy and fibre products

Now is the moment for active participation! Now is the moment for active participation!

There is no There is no wastewaste

when itwhen it’’s bios bio""basedbased